Controller and method for monitoring an opening state of a mechanical

Abstract

A hydrogen supply system 100 includes at least one hydrogen tank 102, 104 fluidly connected to a fuel rail 114 by a pressure regulator 106. The fuel rail 114 is further connected to at least one fuel injector 116 for conveying hydrogen. The controller 110 is configured to monitor the pressure of hydrogen in the fuel rail 114 with the pressure sensor 112, characterized in that the controller 110 is configured to calculate a pressure gradient as a function of the pressure measured by the pressure sensor 112. The controller 110 then compares the pressure gradient with a threshold gradient and obtains a comparison result. Then, the controller 110 detects the on-state of the PRV 108 on the basis of the comparison result. The delivery of hydrogen corresponds to either to an engine combustion chamber or to a fuel cell-based vehicle. And the state and the starting frequency of the PRV108 in the vehicle running process are monitored.

Description

Technical Field

[0001] This invention relates to a controller and method for monitoring the opening status of a mechanical pressure relief valve (PRV) in the pressure regulator of a vehicle's hydrogen supply system. Background Technology

[0002] In hydrogen-powered engine fuel systems or fuel cell systems, variable pressure regulators are used in conjunction with mechanical pressure relief valves (PRVs) to protect the fuel system from overpressure events. When any component of the hydrogen system malfunctions, the PRV opens and releases excess pressure from the fuel supply line. It is necessary to identify and monitor PRV opening events and the number of times they open in order to drive the system to the nearest repair shop in a controlled manner for servicing.

[0003] According to prior art WO17174309, a pressure control system for a gas-operated internal combustion engine and its application are disclosed. This invention relates to a pressure control system for a gas-operated internal combustion engine, the system including a gas pipeline for supplying gaseous fuel to a gas valve, wherein a pressure regulator for adjusting a constant gas pressure is provided in the gas pipeline, and further including a shut-off valve provided in the gas pipeline between the pressure regulator and the gas valve. Summary of the Invention

[0004] This invention proposes a controller for monitoring the opening status of a mechanical pressure relief valve (PRV) in a pressure regulator of a vehicle's hydrogen supply system. The system includes at least one hydrogen tank, which is fluidly connected to a fuel rail via a pressure regulator. The fuel rail is also connected to at least one fuel injector for delivering hydrogen. The controller is configured to:

[0005] The pressure of hydrogen in the fuel rail is monitored using a pressure sensor, where:

[0006] Calculate the pressure gradient based on the pressure measured by the pressure sensor;

[0007] The pressure gradient is compared with the threshold gradient, and the comparison result is obtained.

[0008] The activation status of PRV is detected based on the comparison results.

[0009] Preferably, the controller is configured to increment the counter by 1 each time an on state of PRV is detected.

[0010] Preferably, the controller is configured to record the count in a storage element.

[0011] Preferably, the hydrogen supply system is part of a vehicle based on a hydrogen internal combustion engine.

[0012] Preferably, the hydrogen supply system is part of a vehicle based on a hydrogen fuel cell.

[0013] The present invention also proposes a method for monitoring the opening status of a mechanical pressure relief valve (PRV) in a pressure regulator of a vehicle's hydrogen supply system, the system comprising at least one hydrogen tank fluidly connected to a fuel rail via a pressure regulator, the fuel rail also being connected to at least one fuel injector for delivering hydrogen, the method comprising the following steps:

[0014] The pressure of hydrogen in the fuel rail is monitored using a pressure sensor, where:

[0015] Calculate the pressure gradient based on the pressure measured by the pressure sensor;

[0016] The pressure gradient is compared with the threshold gradient, and the comparison result is obtained.

[0017] The activation status of PRV is detected based on the comparison results.

[0018] Preferably, the method includes incrementing the counter by 1 each time the PRV is detected to be in an on state.

[0019] Preferably, the method includes recording the count in the controller's storage element.

[0020] Preferably, the hydrogen supply system is part of a vehicle based on a hydrogen internal combustion engine.

[0021] Preferably, the hydrogen supply system is part of a vehicle based on a hydrogen fuel cell. Attached Figure Description

[0022] An embodiment of this disclosure is described below with reference to the accompanying drawings, in which:

[0023] Figure 1 A block diagram of a controller for monitoring the opening state of a mechanical pressure relief valve (PRV) in a pressure regulator of a vehicle's hydrogen supply system, according to an embodiment of the present invention, is shown.

[0024] Figure 2 A flowchart is shown of a method according to the present invention for monitoring the opening state of a mechanical pressure relief valve (PRV) in a pressure regulator of a vehicle's hydrogen supply system. Detailed Implementation

[0025] Figure 1A block diagram of a controller for monitoring the opening state of a mechanical pressure relief valve (PRV) in a pressure regulator of a vehicle's hydrogen supply system, according to an embodiment of the present invention, is shown. The system 100 includes at least one hydrogen tank 102, 104, which are fluidly connected to a fuel rail 114 via a pressure regulator 106. The fuel rail 114 is also connected to at least one fuel injector 116 for delivering hydrogen. The controller 110 is configured to monitor the pressure of hydrogen in the fuel rail 114 using a pressure sensor 112, characterized in that the controller 110 is configured to calculate a pressure gradient based on the pressure measured by the pressure sensor 112. The controller 110 then compares this pressure gradient with a threshold gradient and obtains a comparison result. Subsequently, the controller 110 detects the opening state of the PRV 108 based on the comparison result. Hydrogen delivery corresponds to two scenarios: either delivery to an engine combustion chamber or delivery to a fuel cell-based vehicle.

[0026] According to one embodiment of the invention, the controller 110 is configured to increment a counter by 1 each time an on state of the PRV 108 is detected. Furthermore, the controller 110 is also configured to record the counter in a storage element. In one embodiment, the hydrogen supply system 100 is part of a vehicle based on a hydrogen internal combustion engine. In another embodiment, the hydrogen supply system 100 is part of a vehicle based on a hydrogen fuel cell.

[0027] According to the present invention, ECU (Electronic Control Unit) 110 refers to a computing device / unit that includes storage elements such as random access memory (RAM) and / or read-only memory (ROM), analog-to-digital converters (ADCs), digital-to-analog converters (DACs), clocks, timers, and processors (e.g., central processing unit (CPU) capable of machine learning), which are interconnected and connected to other components via communication bus channels on a printed circuit board (PCB). The references to these components are for illustrative purposes only; the number of components may be more or less depending on requirements. The storage elements pre-store mappings, tables, models, modules, logic, instructions, programs, applications, threshold deviations, or values, which are accessed by at least one processor according to a predetermined program. The internal components of ECU 110 are prior art and will not be described in detail here, nor should they be construed as limiting the invention. ECU 110 is capable of communicating via wired and wireless means, such as, but not limited to, Global System for Mobile Communications (GSM), 3G, 4G, 5G, Wi-Fi, Bluetooth, Ethernet, serial networks, Universal Serial Bus (USB) cables, micro-USB, etc.

[0028] Furthermore, the processor can be implemented as any one or a combination of one or more microchips or integrated circuits interconnected via a motherboard; it can also be implemented as hardwired logic, software stored in memory elements and executed by the microprocessor, firmware, application-specific integrated circuits (ASICs), and / or field-programmable gate arrays (FPGAs). The processor is configured to switch and manage the processing work of various artificial intelligence (AI) modules.

[0029] According to the present invention, the operating principle of the controller 110 will be explained. It is assumed that a hydrogen-based internal combustion engine vehicle is in operation and traveling on a road. Monitoring of the PRV 108, located within the pressure regulator 106 of the hydrogen supply system 100, is required. During vehicle operation, fuel is injected from hydrogen storage tanks 102 and 104 into the engine combustion chamber according to the driver's needs. In this process, the fuel passes through the pressure regulator 106, the fuel rail 114, and at least one injector 116. The PRV 108 is located between a proportional valve and a system isolation valve (SIV). The SIV is downstream of the PRV 108. The controller 110 can monitor the operating status of the PRV 108 using signals from the pressure sensor 112.

[0030] When the fuel line pressure (due to regulator malfunction / fuel line wetting, etc.) exceeds the opening pressure limit of PRV108, PRV108 automatically opens and releases the excess line pressure (hydrogen) into the atmosphere through the exhaust line. At this time, the set pressure in fuel rail 114 rises sharply. Therefore, with PRV108 open, the fuel line pressure rises sharply, and pressure sensor 112 mounted on fuel rail 114 captures the pressure value and continuously transmits it to controller 110. Controller 110 calculates the pressure gradient and compares it with a threshold gradient stored in the storage element. If the comparison result shows that the calculated pressure gradient is greater than the threshold gradient, then PRV108 is detected to be open, and the count is incremented by 1. Once the cause of PRV108 opening is resolved, the count of PRV108 in the storage element can be reset using appropriate tools.

[0031] Figure 2A flowchart of a method for monitoring the opening state of a mechanical pressure relief valve (PRV) in a pressure regulator of a vehicle's hydrogen supply system, according to the present invention, is shown. The system 100 includes at least one hydrogen tank 102, 104, which are fluidly connected to a fuel rail 114 via a pressure regulator 106. The fuel rail 114 is also connected to at least one fuel injector 116 for delivering hydrogen. The method includes several steps, wherein step 202 includes: a controller 110 monitoring the pressure of hydrogen in the fuel rail 114 using a pressure sensor 112. The method is characterized by step 204, which includes: the controller 110 calculating a pressure gradient based on the pressure measured by the pressure sensor 112. Step 206 includes: the controller 110 comparing the pressure gradient with a threshold gradient and obtaining a comparison result. Step 208 includes: the controller 110 detecting the opening state of the PRV 108 based on the comparison result. The method is performed by the controller 110 in the vehicle.

[0032] According to this method, the pressure in the fuel rail rises sharply from a set pressure to the opening pressure set by PRV108 to release gas. The method determines a pressure gradient and compares it to a threshold pressure. The method includes incrementing a counter by 1 each time the opening state of PRV108 is detected. Furthermore, the method includes recording the counter in a storage element of controller 110. According to the invention, this method is applicable to hydrogen supply system 100, which is part of a hydrogen internal combustion engine-based vehicle or a hydrogen fuel cell-based vehicle.

[0033] According to the present invention, a controller 110 and method for detecting and counting the opening status of a pressure relief / limiting valve (PRV108 or PLV) in a hydrogen engine / fuel cell vehicle are disclosed. The controller 110 can now monitor the status and opening frequency of the PRV108 during vehicle operation, thereby achieving smooth and safe driving. The controller 110 acts as a virtual sensor for the mechanical PRV108.

[0034] It should be understood that the embodiments described above are merely exemplary and do not limit the scope of the invention. Many such embodiments, as well as other modifications and variations to the embodiments described above, are conceivable. The scope of the invention is defined only by the scope of the claims.

Claims

1. A controller (110) for monitoring the opening state of a mechanical pressure relief valve (PRV) (108) in a pressure regulator (106) of a vehicle's hydrogen supply system (100), the system (100) including at least one hydrogen tank (102, 104) fluidly connected to a fuel rail (114) via the pressure regulator (106), the fuel rail (114) also being connected to at least one fuel injector (116) for delivering hydrogen, the controller (110) being configured to: The method of monitoring hydrogen pressure in the fuel rail (114) using a pressure sensor (112) is characterized by: The pressure gradient is calculated based on the pressure measured by the pressure sensor (112); The pressure gradient is compared with the threshold gradient, and the comparison result is obtained. The on / off state of the PRV (108) is detected based on the comparison results.

2. The controller (110) according to claim 1, which is configured to increment a counter by 1 each time the on state of the PRV (108) is detected.

3. The controller (110) according to claim 2, which is configured to record the count in a storage element.

4. The controller (110) according to claim 1, wherein, The hydrogen supply system (100) is part of a vehicle based on a hydrogen internal combustion engine.

5. The controller (110) according to claim 1, wherein, The hydrogen supply system (100) is part of a vehicle based on a hydrogen fuel cell.

6. A method for monitoring the opening status of a mechanical pressure relief valve (PRV) (108) in a pressure regulator (106) of a hydrogen supply system (100) of a vehicle, said system (100) including at least one hydrogen tank (102, 104) fluidly connected to a fuel rail (114) via the pressure regulator (106), said fuel rail (114) also connected to at least one fuel injector (116) for delivering hydrogen, said method comprising the steps of: The method of monitoring hydrogen pressure in the fuel rail (114) using a pressure sensor (112) is characterized by: The pressure gradient is calculated based on the pressure measured by the pressure sensor (112); The pressure gradient is compared with the threshold gradient, and the comparison result is obtained. The on / off state of the PRV (108) is detected based on the comparison results.

7. The method of claim 6, wherein the count is incremented by 1 each time the on state of the PRV (108) is detected.

8. The method of claim 7, further comprising recording the count in a storage element of the controller (110).

9. The method according to claim 6, wherein, The hydrogen supply system (100) is part of a vehicle based on a hydrogen internal combustion engine.

10. The method according to claim 6, wherein, The hydrogen supply system (100) is part of a vehicle based on a hydrogen fuel cell.

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